Manufacturing method for metal plate with openwork pattern

Abstract

A manufacturing method for a metal plate with a novel openwork pattern with depth is provided. A plate 3 including a portion having a thickness of 3 mm or less is embedded between an upper side 1 and a lower mold 2, which are sand molds; the upper mold 1 and the lower mold 2 are separated; the plate 3 is removed; the upper mold 1 and the lower mold 2 are combined; and molten metal 19 is poured into a gap made by the removing of the plate 3.

Description

TECHNICAL FIELD

[0001] The present invention relates to a manufacturing method for a metal plate with an openwork pattern.BACKGROUND ART

[0002] Conventionally, metal plates with openwork patterns have existed, but such openwork patterns of metal plates have commonly been traditional patterns of flowering plants and other motifs, and have been thick and without movement or originality.SUMMARY OF THE INVENTIONPROBLEM TO BE SOLVED BY THE INVENTION

[0003] Considering the actual circumstances described above, the present invention is directed to provide a manufacturing method for a metal plate with a novel openwork pattern with depth that is thin, lightweight, delicate, and vibrant.MEANS FOR SOLVING THE PROBLEMS

[0004] To overcome the aforementioned problems, a manufacturing method for a metal plate with an openwork pattern according to an invention according to claim 1 includes: embedding a plate including a portion having a thickness of 3 mm or less between an upper side and a lower mold, which are sand molds; separating the upper mold and the lower mold; removing the plate; combining the upper mold and the lower mold; and pouring molten metal into a gap made by the removing of the plate, so that the openwork pattern is irregular and is formed in a portion of the gap at which the gap is 3 mm or less thick, wherein the plate is configured by combining clay plates of different thicknesses in a mosaic pattern.

[0005] A manufacturing method for a metal plate with an openwork pattern according to an invention according to claim 2 includes: embedding a plate including a portion having a thickness of 3 mm or less between an upper side and a lower mold, which are sand molds; separating the upper mold and the lower mold; removing the plate; combining the upper mold and the lower mold; and pouring molten metal into a gap made by the removing of the plate, so that the openwork pattern is irregular and is formed in a portion of the gap at which the gap is 3 mm or less thick, wherein the plate is formed of clay, and is partially carved or built up.EFFECTS OF THE INVENTION

[0006] A manufacturing method for a metal plate with an openwork pattern according to the invention according to claim 1 includes: embedding a plate including a portion having a thickness of 3 mm or less between an upper side and a lower mold, which are sand molds; separating the upper mold and the lower mold; removing the plate; combining the upper mold and the lower mold; and pouring molten metal into a gap made by the removing of the plate, so that the openwork pattern is formed to have an irregular and sometimes unexpectable lace pattern, which allows manufacturing of a metal plate with a novel openwork pattern with depth that is lightweight and full of delicacy and vibrancy.

[0007] Furthermore, according to the manufacturing method for the metal plate with the openwork pattern according to the invention according to claim 1, the plate is configured by combining clay plates of different thicknesses in a mosaic pattern, which allows the arrangement of an openwork pattern having a lace pattern with different area percentages of light-transmitting portions within one metal plate; and a metal plate with an openwork pattern that has even more novelty and depth can be manufactured.

[0008] According to the manufacturing method for the metal plate with the openwork pattern according to the invention according to claim 2, the plate is formed of clay and is partially carved or built up, which makes it possible to intentionally form transparent portions and non-transparent portions, which allow enhanced artistry.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] [FIGS. 1A to 1C] FIGS. 1A to 1C are explanatory drawings showing manufacturing processes of a metal plate with an openwork pattern of the present invention. [FIGS. 1D and 1E] FIGS. 1D and 1E are explanatory drawings showing manufacturing processes of the metal plate with the openwork pattern of the present invention (continuing from FIGS. 1A to 1C). [FIGS. 2A to 2D] FIGS. 2A to 2D are photographs showing states of the openwork pattern for each gap size. [FIG. 3] FIG. 3 is a photograph showing an example of the metal plate with the openwork pattern of the present invention in use. [FIG. 4] FIG. 4 is a plan view showing an example of a plate used when manufacturing the metal plate. MODE FOR CARRYING OUT THE INVENTION

[0010] Embodiments of the present invention will now be described based on the drawings. FIGS. 1A to 1C and FIGS. 1D and 1E show manufacturing processes of a metal plate with an openwork pattern of the present invention.

[0011] First, as shown in FIG. 1A, multiple plates 4a, 4b, 4c, 4d, ..., having different thicknesses are made from clay. The thicknesses of the plates 4a, 4b, 4c, 4d, ..., are, for example, 4 mm, 3.5 mm, 3 mm, 2.5 mm, 2 mm, 1 mm, and 0.5 mm.

[0012] Then, as shown in FIG. 1B, the plates 4a, 4b, 4c, 4d, ..., which are formed of clay and have different thicknesses, are combined in a mosaic pattern to make one plate 3, which is placed on a lower mold 2 in which sand 6 is packed into a box 5. At this time, grooves 7 may be formed by carving the plate 3; and the plate 3 may be built up by adding cord-shaped clay 8.

[0013] Then, as shown in FIG. 1C, the box 5 of an upper mold 1 is placed on the box 5 of the lower mold 2 and packed with the sand 6.

[0014] Then, as shown in FIG. 1D, the upper mold 1 and the lower mold 2 are separated, and the embedded plate 3 is removed.

[0015] Then, as shown in FIG. 1E, the upper mold 1 and the lower mold 2 are combined, and molten metal 19, specifically copper or a copper alloy at 1,000 to 1,200°C, is poured into the gap made by removing the plate 3.

[0016] Subsequently, the upper mold 1 and the lower mold 2 are separated, and the metal plate is removed.

[0017] In the metal plate manufactured by the processes described above, molten metal flows into a portion of the gap at which the gap is 3 mm or less thick, thereby forming an openwork pattern 12 having an irregular lace pattern with different area percentages of light-transmitting portions (transparent portions) for each gap size as shown in FIGS. 2A to 2D. It is clear from these photographs that the molten metal 19 flows into the gap more easily as the size of the gap increases, which reduces the area percentage of light-transmitting portions (see FIG. 2A), and the molten metal 19 flows into the gap less easily as the size of the gap decreases, which increases the area percentage of light-transmitting portions (see FIG. 2D).

[0018] Results of experiments performed by the applicant showed that a lace-shaped openwork pattern 12 having an area percentage of light-transmitting portions of 65 to 45% is obtained when the size of the gap is 0.5 to 1 mm; a lace-shaped openwork pattern 12 having an area percentage of light-transmitting portions of 40 to 20% is obtained when the size of the gap is 1.0 to 2.5 mm; and a lace-shaped openwork pattern 12 having an area percentage of light-transmitting portions of 20 to 10% is obtained when the size of the gap is 2.5 to 3.5 mm.

[0019] Furthermore, partially carving the clay plate 3 embedded in the mold prevents the molten metal 19 from flowing into the carved portion; conversely, building up the clay plate 3 allows the molten metal 19 to flow into the built up portion; therefore, transparent portions and non-transparent portions can be intentionally formed to enhance the artistry.

[0020] FIG. 3 shows an example of the metal plate 9 with the openwork pattern according to the present invention in use, and shows an example in which the metal plate 9 is mounted in front of a mirror 10. The metal plate 9 with the openwork pattern has a quadrilateral exterior shape with a large substantially circular hole 11 formed at the central portion; and the irregular lace-shaped openwork pattern 12 is formed around the hole 11.

[0021] FIG. 4 shows an example of the plate 3 used when manufacturing the metal plate 9 with the openwork pattern. As shown in FIG. 4, the plate 3 is configured by combining five types of clay plates 4a, 4b, 4c, 4d, and 4e that have thicknesses of 4 mm, 3 mm, 2.5 mm, 2 mm, and 1 mm. The clay plate 4a that has a thickness of 4 mm is used in the surrounding quadrilateral frame-shaped portion 13; the clay plate 4b that has a thickness of 3 mm is used in the portion between the frame-shaped portion 13 and the outer circle 14; the clay plate 4c that has a thickness of 2.5 mm is used in the portion between the outer circle 14 and the inner quadrilateral 15; the clay plate 4d that has a thickness of 2 mm is used in the portion between the inner quadrilateral 15 and the inner circle 16; and the clay plate 4e that has a thickness of 1 mm is used inside the inner circle 16.

[0022] Then, sprue runners 17 are formed at both the left and right sides of the plate 3; and multiple weirs 18 are provided from the sprue runners 17 across to the surrounding quadrilateral frame-shaped portion 13. The mold in which the upper mold 1 and the lower mold 2 are combined is set upright, and the molten metal 19 is poured through gates 20 located at the upper end portions of the sprue runners 17.

[0023] The clay plate 4a that has a thickness of 4 mm is used in the surrounding frame-shaped portion 13, allowing the molten metal 19 to flow into the entire portion 13. The combination of the clay plates 4b, 4c, and 4d having different thicknesses is used between the surrounding frame-shaped portion 13 and the center circle 16, and so an irregular and complex lace-shaped openwork pattern 12 is formed between the surrounding frame-shaped portion 13 and the center circle 16 (see FIG. 3).

[0024] The manufacturing method for the metal plate with the openwork pattern according to the present invention described above includes: embedding the plate 3 including a portion having a thickness of 3 mm or less between the upper side 1 and the lower mold 2, which are sand molds; separating the upper mold 1 and the lower mold 2; removing the plate 3; combining the upper mold 1 and the lower mold 2; and pouring the molten metal 19 into the gap made by removing the plate 3, so that an irregular and sometimes unexpectable lace-shaped openwork pattern 12 is formed, which allows the manufacture of the metal plate 9 with a novel openwork pattern with depth that is lightweight and full of delicacy and vibrancy.

[0025] According to the manufacturing method for the metal plate with the openwork pattern according to the present invention, the plate 3 is configured by combining clay plates 4a, 4b, 4c, 4d, ..., having different thicknesses in a mosaic pattern, so that the openwork pattern 12 can be arranged to have a lace pattern with different area percentages of light-transmitting portions within one metal plate 9; and the metal plate 9 with an even more novel and deeper openwork pattern can be manufactured.

[0026] Furthermore, according to the manufacturing method for the metal plate with the openwork pattern according to the present invention, the plate 3 is formed of clay and is partially carved or built up, which makes it possible to intentionally form transparent portions and non-transparent portions, which allows enhanced artistry.

[0027] The present invention is not limited to the embodiments above. The plate that is embedded between the upper mold and the lower mold may have any material composition or shape as long as a portion having a thickness of 3 mm or less is at least partially included. The method (plan) for pouring the molten metal into the gap formed between the upper mold and the lower mold is arbitrary. The metal is not limited to copper or a copper alloy, and may be iron, aluminum, etc. Applications of the metal plate with the openwork pattern according to the present invention are not particularly limited, and the metal plate can be used, for example, in mirrors, frames, doors, partitions, and other decorations, and can be used alone for ornamental purposes.REFERENCE NUMERAL LIST

[0028] 1 upper mold 2 lower mold 3 plate 4a, 4b, 4c, 4d, 4e clay plate

Claims

1. A manufacturing method for a metal plate with an openwork pattern, comprising: embedding a plate between an upper side and a lower mold, the plate including a portion having a thickness of 3 mm or less, the upper mold and the lower mold being sand molds; separating the upper mold and the lower mold; removing the plate; combining the upper mold and the lower mold; and pouring molten metal into a gap made by the removing of the plate, so that the openwork pattern is irregular and is formed in a portion of the gap at which the gap is 3 mm or less thick, wherein the plate is configured by combining clay plates of different thicknesses in a mosaic pattern.

2. A manufacturing method for a metal plate with an openwork pattern, comprising: embedding a plate between an upper side and a lower mold, the plate including a portion having a thickness of 3 mm or less, the upper mold and the lower mold being sand molds; separating the upper mold and the lower mold; removing the plate; combining the upper mold and the lower mold; and pouring molten metal into a gap made by the removing of the plate, so that the openwork pattern is irregular and is formed in a portion of the gap at which the gap is 3 mm or less thick, wherein the plate is formed of clay and is partially carved or built up.

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